Electrical testing standards for automotive manufacturing
Electrical testing requirements for automotive manufacturing are becoming more complex. This is driven by several factors, including the growing demand for advanced driver assistance systems (ADAS) and autonomous driving technologies, the shift toward electrification of vehicles, and the increasing use of software and electronics in automotive systems.
As a result, the electrical testing requirements for automotive manufacturing have evolved to include more comprehensive and specialized testing protocols to ensure the safety, reliability, and performance of the complex electrical systems and components used in modern vehicles.
This article provides an overview of the electrical testing standards for automotive manufacturing, the difference in requirements for electrical vehicle production. It also discusses the types of test systems available on the market to achieve this increasingly complex set of requirements.
Electrical testing standards for automotive manufacturing
There are several electrical testing standards used in automotive manufacturing to ensure that the electrical components and systems in a vehicle meet the required safety and performance standards. Some of these standards are:
- Automotive EMC (Electromagnetic Compatibility) Standards: EMC standards ensure that electrical components and systems in a vehicle do not produce excessive electromagnetic emissions that can interfere with other electronic devices. The main EMC standards used in automotive manufacturing are CISPR25, ISO 11452, and ISO 7637.
- Automotive Electrical Testing Standards: These standards ensure that the electrical components and systems in a vehicle meet the required safety and performance standards. The main electrical testing standards used in automotive manufacturing are ISO 16750, SAE J1113, and IEC 61980.
- Automotive Environmental Testing Standards: These standards ensure that the electrical components and systems in a vehicle can withstand the harsh environmental conditions they may be exposed to during their lifetime. The main environmental testing standards used in automotive manufacturing are ISO 20653, ISO 16750, and SAE J1211.
- Automotive Reliability and Durability Standards: These standards ensure that the electrical components and systems in a vehicle can function reliably and durably over their expected lifespan. The main reliability and durability testing standards used in automotive manufacturing are IEC 60068, ISO 16750, and SAE J1211.
- Automotive Safety Standards: These standards ensure that the electrical components and systems in a vehicle do not pose any safety hazards to the occupants or the environment. The main safety standards used in automotive manufacturing are ISO 26262 and IEC 61508.
Automotive manufacturers use a combination of these standards to test the electrical components and systems in a vehicle to ensure that they meet the required safety and performance standards. Testing is conducted at various stages of the manufacturing process, including design, development, prototype testing, and production testing.
Differences in electrical testing standards for electric vehicles compared to standard vehicles
Electrical testing standards for electric vehicles differ to the requirements for standard vehicles. This is because electric vehicles have unique electrical systems and components, such as batteries, motors, and power electronics, that require specific testing to ensure their safety and performance. Some of the main differences in electrical testing standards for electric vehicles are:
- Electrical Safety Standards: Electric vehicles have high-voltage electrical systems that require special safety measures to prevent electric shock hazards. The electrical safety standards for electric vehicles are more stringent than those for standard vehicles, and they include specific requirements for electrical isolation, grounding, and protective systems.
- Battery Testing Standards: Electric vehicle batteries must be tested to ensure their safety and performance. The battery testing standards for electric vehicles include specific requirements for battery capacity, voltage, temperature, and charging and discharging cycles.
- Charging Standards: Electric vehicle charging systems must be tested to ensure their safety and performance. The charging standards for electric vehicles include specific requirements for charging connectors, charging protocols, and charging safety features.
- Electromagnetic Compatibility Standards: Electric vehicles have high-power electrical systems that can produce electromagnetic emissions that may interfere with other electronic devices. The electromagnetic compatibility standards for electric vehicles include specific requirements for electromagnetic emissions and immunity testing.
- Functional Safety Standards: Electric vehicles have complex electrical systems that must operate safely and reliably in various driving conditions. The functional safety standards for electric vehicles include specific requirements for safety-related systems, such as the high-voltage electrical system, battery management system, and motor control system.
Overall, the electrical testing standards for electric vehicles are more comprehensive and stringent than those for standard vehicles due to the unique electrical systems and components used in electric vehicles.
Electrical test equipment for the automotive industry
As the electrical systems in vehicles grow more complex, it’s vital to ensure the correct test procedures and equipment are used to comply with industry standards. Balancing these increased technical requirements with maintaining or improving manufacturing efficiencies is a constant challenge for the sector.
Harness test systems are used to test the wiring harnesses to ensure that they are functioning correctly and meet the required specifications and standards. The tests performed include continuity checks, insulation resistance testing and high voltage testing. Other tests specific to EVs include checking for proper communication between different electrical components.
As the electrical systems and wiring harness in both standard and electric vehicles becomes ever more complex, test systems need to be able to achieve more rigorous testing at higher voltages and current than previously required.
How we can help
MK Test Systems are specialist suppliers for test equipment to the automotive sector as well as aerospace, defence and rail. With the growing complexity of electrical testing, we can provide consultancy and advice on implementing a test system capable of managing the growing requirements for automotive manufacturers.
An overview on our work in the automotive sector can be found here.